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Advanced Process Possibilities in Friction Crush Welding of Aluminum, Steel, and Copper by Using an Additional Wire

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Abstract

Joining sheet metal can be problematic using traditional friction welding techniques. Friction crush welding (FCW) offers a high speed process which requires a simple edge preparation and can be applied to out-of-plane geometries. In this work, an implementation of FCW was employed using an additional wire to weld sheets of EN AW5754 H22, DC01, and Cu-DHP. The joint is formed by bringing together two sheet metal parts, introducing a wire into the weld zone and employing a rotating disk which is subject to an external force. The requirements of the welding preparation and the fundamental process variables are shown. Thermal measurements were taken which give evidence about the maximum temperature in the welding center and the temperature in the periphery of the sheet metals being joined. The high welding speed along with a relatively low heat input results in a minimal distortion of the sheet metal and marginal metallurgical changes in the parent material. In the steel specimens, this FCW implementation produces a fine grain microstructure, enhancing mechanical properties in the region of the weld. Aluminum and copper produced mean bond strengths of 77 and 69 pct to that of the parent material, respectively, whilst the steel demonstrated a strength of 98 pct. Using a wire offers the opportunity to use a higher-alloyed additional material and to precisely adjust the additional material volume appropriate for a given material alignment and thickness.

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Acknowledgments

The authors would like to thank Werner Saft, Maximilian Rehm and German Zeller (Laboratory for Joining and Welding), Professor Dierk Hartmann and Petra Schittenhelm (Laboratory for Material Sciences) and Jochen Ringholz (Laboratory of Energy Technology) at Kempten University of Applied Sciences, Germany, for their support.

Funding

This research did not receive any specific grant from funding agencies in the public, commercial, or not-for-profit sectors.

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Authors and Affiliations

  1. Department of Engineering, Kempten University of Applied Sciences, 87435, Kempten, Germany

    Florian A. Besler, Paul Schindele & Michael J. R. Stegmüller

  2. Department of Mechanical and Marine Engineering, Western Norway University of Applied Sciences, Postboks 7030, 5020, Bergen, Norway

    Florian A. Besler, Richard J. Grant & Michael J. R. Stegmüller

  3. Department of Engineering and Applied Physics, Glyndwr University, Wrexham, LL11 2AW, UK

    Florian A. Besler & Richard J. Grant

Authors
  1. Florian A. Besler
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  2. Richard J. Grant
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  3. Paul Schindele
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  4. Michael J. R. Stegmüller
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Corresponding author

Correspondence to Florian A. Besler.

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Manuscript submitted March 29, 2017.

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Besler, F.A., Grant, R.J., Schindele, P. et al. Advanced Process Possibilities in Friction Crush Welding of Aluminum, Steel, and Copper by Using an Additional Wire. Metall Mater Trans B 48, 2930–2948 (2017). https://doi.org/10.1007/s11663-017-1108-4

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  • DOI: https://doi.org/10.1007/s11663-017-1108-4

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